Carton palletizing apparatus



May 6, 1969 E, E, ROTH ET AL 3,442,400

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CARTON PALLETIZING APPARATUS Filed March 2, 1967 Sheet 6 of 11 DEFt 6702sraiug up E 2 3 ,4 [19M 5w H flSsEMBL r l .5 2 (409/495 4 our 35 7 A 54' twee/44: j I 155 4 5 47 I25 A a/5r Fl G I7 3 #5 '4 5| l/l/Jr 701.0695

May 6, 1969 E. E. ROTH ET CARTON PALLETIZING APPARATUS Sheet Filed March2, 1967 May 6, 1969 ROTH ET AL CARTON PALLETIZING APPARATUS m of- 11 Sheet Filed March 2, 1967 hm QM NM H w Q m W fi 2 a g $7M Z May 6, 1969 vROTH ET AL 7 3,442,400

CARTON PALLETIZING APPARATUS Filed March 2. 1967 Sheet. of 11 FIG 2O FIG2I m/m-wrazss ADP/V6.97 5. Pane max/er 1 mwmew M Mal/W United StatesPatent US. Cl. 214- 6 6 Claims ABSTRACT OF THE DISCLOSURE Cartonpalletizing apparatus in which elevator means is movable between a lowercarton receiving position and an elevated carton storing position, meansbeing located in the carton storing position in the form of tines whichare insertable between the rollers forming the bed of the elevator meansso as to be moved inwardly coincidentally with the elevator means totake over support and temporary storage of the cartons while theelevator means is lowered to the first position to receive additionalcartons. The apparatus is capable of handling a plurality of cartons ina layered pattern and storing a plurality of layers until a suitablestack has been formed, which stack may then the deposited on a palletfor transportation and subsequent handling.

A carton palletizing apparatus of substantially floor level layout inwhich cartons are fed to make-up compact patterns of cartons on acontinuously operating powered roller table and then transferred aspatterns to a stacking device. The stacking device sequentially elevateseach pattern of cartons and retains the same in elevated position suchthat 'a stack of patterns is built up from the bottom until a desirednumber of layers is collected. The stacking device then receives apallet and raises the pallet under the stack where the stack istransferred onto the pallet and the thus loaded pallet is lowered andconveyed away or removed by suitable means, as by a forklift truck. Theapparatus is provided with a system of controls that can formpredetermined patterns, arrange for interlocked layers in a stack, andgenerally operate substantially automatically so long as the cartons arecontinuously supplied.

Palletizing apparatus heretofore available to the industry has generallyinvolved large, high rise, and expensive mechanism that is complicatedto manufacture, is cumbersome to ship to the place of use and set upproperly, and is large and high so that carton feeding conveyor systemsare rendered expensive to set up. Most of the prior apparatus has beendesigned to stack layers of cartons from the top, thus demanding heightin the apparatus to accommodate the top stacking mode of operation.

The important objects of the present invention are to overcome theproblems of construction, the size of apparatus, the high levelconveyance and handling of cartons, and the complications and expensesnormally associated with prior apparatus.

Other important objects of the present invention are to provide a lowlevel, table heighth apparatus that utilizes relatively standardcomponents, improved stacking means for layering patterns of cartonsfrom the bottom to accelerate the pelletizing operation, and reductionin the construction costs, expense of shipment of the total apparatus byhaving smaller and less bulky units.

There is disclosed herein certain preferred forms of palletizingapparatus which illustrate the principles of this invention, said formsbeing disclosed in more detail in the following description whenconsidered in view of the accompanyng drawings, wherein:

FIG. 1 is a plan view of carton palletizing apparatus 'ice illustratinga preferred form and organization of components;

FIG. 2 is a longitudinal and partly sectional view of the apparatus asseen along line 22 in FIG. 1;

FIG. 3 is a perspective view of the table frame utilized in theapparatus of FIG. 1;

FIG. 4 is a fragmentary perspective view of a component in the apparatusof FIG. 1, the showing being on an enlarged scale taken from below thetable frame;

FIG. 5 is an enlarged fragmentary view of the stop means in the conveyorsystem of the apparatus;

FIG. 6 is an enlarged transverse sectional view taken at line 66 in FIG.1;

FIG. 7 is an enlarged fragmentary sectional view taken at line 7-7 inFIG. 6;

FIG. 8 is a greatly enlarged and fragmentary sectional view of thestacking device in the apparatus of FIG. 1, the view being taken alongline 8-8 thereof;

FIG. 9 is a partly sectional plan view of the stacking device as seenalong line 9-9 in FIG. 8;

FIG. 10 is a simplified perspective view of the stacking device shown inFIG. 8;

FIG. 11 is a schematic view of the action of the pattern control guidemeans associated with the apparatus of FIG. 1;

FIG. 12 is a fragmentary detail view of the stabilizing means for theelevating table shown in FIG. 8;

FIG. 13 is a typical compacting dam and actuating means to lock andrelease the dam, the means being incorporated in pairs of the stackingdevice of FIG. 8;

FIG. 14 is a fragmentary sectional View of the coordinated carton stopmeans employed with the elevating table in the stacking device of FIG.1;

FIG. 15 is also a fragmentary sectional view of the braking meansemployed to stop the rollers in the elevating table of the stackingdevice of FIG. 1;

FIGS. 16A through 16F are schematic elevational views of the sequentialsteps in the operation of the carton stacking device of FIG. 1;

FIG. 17 is a greatly simplified circuit diagram by which the severalfunctions and sequential steps of the palletizing apparatus of FIG. 1may be coordinated and controlled;

FIG. 18 is a schematic plan view of the apparatus embodying the controlsystem of FIG. 17;

FIG. 19 is a plan view of a modified palletizing apparatus embodying thecomponents and control features illustrated in the foregoing View, butenlarged to include pallet loading and loaded pallet discharge;

FIG. 20 is a plan view of another modification for forming cartonpatterns; and

FIG. 21 is still another plan view of a modified palletizing apparatusfor forming carton patterns.

Turning now to FIGS. 1, 2 and 3, the palletizing apparatus A isorganized on a low level table structure (FIG. 3) which includeslongitudinal side members 23,

. 24, 25, 26 and 27, and supported by pairs of legs 28,

29 and 30. A series of load supporting rollers are suitably supported atthe opposite ends in the side members 21 and 22, the rollers beingarranged in groups, as follows: The group of rollers 31 comprise acarton receiving section on the table; the next group of rollers 32comprise a carton pattern collecting section on the table; and the nextgroup of rollers 33 comprise a carton compacting and loading section onthe table. Between the groups of rollers 31 and 32 there is positioned alarge diameter carton turning roll 34 which cooperates with adjustablyfixed turning abutments 35 located at the opposite ends of the turningroll 34. Each abutment 35 is faced with a friction pad 36 which retardsthe sliding action of a corner or other part of a carton to the extentthat the carton swings or pivots into a position rotated about 90degrees from its alignment when issuing from between a pair of patterncontrol guides 37. The pivoting carton passes over the turning roll 34and is quickly stabilized in its correct turned attitude.

Between the group of rollers 32 and 33 there is a stop roll 38 which mayon command rise above the upper load supporting surface of rollers 32 tostop passage of cartons. At the end of the group of rollers 33 there isanother stop roller 39 which also on command rises above the top surfaceof rollers 33 to stop the passage of cartons. The supply of cartons isobtained from a conventional roller conveyor the end of which is seen at40. Between this conveyor 40 and the rollers 31 there is disposed acarton speed-up belt conveyor 41 whereby cartons arriving in end to endabutment from conveyor 40 can be separated to create a desired spacingso that each carton can proceed to move between the control guides 37.The group of rollers 31 also is operated to increase the carton spacingso that little opportunity is afforded for carton pile up, unless anobstruction develops.

As an example of the belt and roller drive means there is seen in FIG. 2a drive motor 42 mounted on the legs 43 of the belt conveyor frame. Themotor 42 is connected by sprocket chain 44 to the end of the belt driveroll 45. The belt 4.1 is trained over a roll 46 and returns through aslack take-up device 47. The roll 46 drives a gear 48 which meshes witha direction reversing gear 49 (FIG. 1) of a speed gear 50. The speedgear 50 drives a belt 51 passing in driving engagement under the groupof rollers 31 and runs through a slack take-up device 52. The turningroller 34 has a separate drive by sprocket chain 53 from motor 54. Allof the rollers 32 and 33 are driven from a common motor 55 and sprocketchain 55a, the drive belt 56 passing against the under side of theserollers and through a slack take-up device 57. In one preferredapparatus A, and to illustrate the operation thereof, the cartons werefed by conveyor 40 at about 50 f.p.rn. and accelerated by belt 41 toabout 137 f.p.m. to effect a spacing thereof. Each carton on reachingthe rollers 31 was speeded up to about 148 f.p.m. to increase thespacing due to the action of the pattern control guides 37 in fanningback and forth widthwise of the rollers 31, as will be explainedpresently. The turning roller 34 was driven at a speed to move thecartons at about 210 f.p.m. to complete carton turning rapidly andstabilize the turned position, after which the rollers 32 and 33 weredriven to effect carton movement at about 180 f.p.m. to effect thecollecting and movement of cartons in a pattern. Of course, other linearspeeds can be selected, depending upon the character of carton contentsand weight, and in this connection the term carton shall be taken tomean any article, case, bag or box which has suificient shape retentionability to be caused to turn by the action of the fraction surfaces 36and roll 34, and be responsive to pushing so as to move into a compactpattern.

Still with reference to FIGS. 1, 2, 4 and 5, it is seen that the groupsof powered rollers 31, 32 and 33 assemble and advance patterns ofcartons that have been selected for make-up by the control guides 37. Inthe section of rollers 31 there are adjustable supports 58 for locatingthe abutments 35 which initiate carton turning. Beyond the abutments 35there are guide rails 59 and 60 fixed in position over the group ofrollers 32 to act to keep the cartons together in some semblance of thedesired pattern. Adjacent the ends of rails 59 and 60, there is the stoprail 38 which on command is raised above the top line of rollers 32.Actuation of stop roller 38 is effected by a pair of bellcranks 61 (onebeing shown in FIGS. 2 and located at the ends of the roller 38. Thebellcrank 61 has its arm 62 (FIG. 5) actuated by the rod 63 of apressure cylinder motor 64. The base end of the motor 64 is pivoted in abracket 65 carried by the frame side member 21.

4 The side not shown is similar to what has just been described. Whenthe roller 38 is down it bridges the last roller 32 and the first roller33. In a like manner stop roller 39 is actuated by pressure cylindermotor means 64' moving bellcranks 66 (FIG. 1).

The group of rollers 33 support a pattern of cartons generally assemblednear the adjustable guide 67 carried by the frame side member 21.Opposite the guide 67 is a compacting ram 68 which moves over therollers 33 to compact the cartons against the guide 67 and align thepattern for movement out of the compacting section of rollers 33. Theram 68 is connected by a pair of rods 69 (one being seen in FIG. 4) toslides 70 which move on guide rods 71. The guide rods 71 are supportedin and between side member 22 and an intermediate member 72 (see FIG.3). The slides 70 are cross connected by straps 73, and one strap 73 hasan arm 74 to which the end of piston rod 75 is connected. The rod 75 isactuated by the cylinder motor 76 supported by bracket 77 from sidemember 22.

As is seen in FIG. 2, the drive means 51, 53 and 56 for the rollers 31,34 and 32-33 are operatively supported in the frame (FIG. 3) between theside member 21 and intermediate members 78 and 79. A typical support forthe belt means 51 is seen in FIG. 6 where the pulley 80, support belt51, and the pulley shaft 81 is driven by a sprocket wheel 82 andsprocket chain 82' from gear 50 (FIG. 2). In addition to supporting thepulley 80, the member 78 and a spaced parallel angle member 82 (FIG. 6)support a pair of rods 83 on which slides an actuator 84 (FIG. 7) havinga pair of fingers 85 engaged in slots 86 in the lower flanges '87 of thepattern control guides 37. As is seen in FIGS. 6 and 7, the controlguides 37 have the carton entrance ends pivoted on shafts 88 supportedby the frame cross member 27 on an extension base 89. The actuator 84 isconnected to a piston-cylinder motor means 90, the piston rod 91 ofwhich is attached to the drive boss 92 on the actuator and the cylinderof which is attached to the intermediate member 78. The motion ofactuator 84 is monitored by a group of cams contained in a box 93 andactuated by the shaft 94 driven by sprocket 95 and chain 96. The chainends are attached to the boss 92, and one loop of the chain runs overthe idler sprocket 97 while the other runs over the cam shaft sprocket95.

Looking now at FIG. 11, and with due regard to the plan view of FIG. 1,there is shown somewhat diagrammatically the operation of the patterncontrol guides 37 in order to make up a pattern of eight cartons. Inorder to make up such a pattern of cartons the control guides 37 must befanned crosswise of the carton supporting rollers 31 in the receivingsection of the table to six different settings. For example, the controlguides 37 must initially be positioned in the direction represented bythe broken line 1 such that the carton Cl passes between the controlguides 37 and is picked up by the acceleration roller 34 withoutengaging or brushing against the friction surface 36 on the sideabutment 35. Thus carton C1 will proceed straight into its patternposition. The control guides 37 are then moved to position 2 asrepresented by the broken line 2 where carton C2 is directed straight 1nand passes over the roller 34 to assume its position along side ofcarton C1. At this point the control guides 37 are fanned in acounterclockwise direction to a positron represented by broken lines 34,where cartons C3 and C4 in succession are directed so that the leadingcorner thereof brushes against the friction surface 36 on the abutment35, causing the cartons to start a turning operation which is stabilizedby the acceleration roller 34 such that each of the cartons is turned tothe cartons C1 and C2. Immediately following the passage of carton C4the control guides 37 are fanned in a clockwise direction to a positionrepresented by broken lines 5-6 where successive cartons C5 and C6 aredirected against the friction surface 36 of abutment 35 to effect a 90turn before passing into the pattern of the cartons previouslycollected. The control guides 37 are then moved to the positionrepresented by broken line 7 where carton C7 is directed straightthrough to take its position along side of the turned carton C5 and C6.This is followed by the guides being positioned as represented by thebroken line 8 where the final carton C8 passes into the pattern withoutbeing turned. The foregoing description relates to the forming of apattern of eight cartons which is assembled against the stop roller 38in a loose fashion. At this time the stop roller 38 is retracted intothe surface of the rollers 32 and the loose pattern is advanced to thestop roller 39. Once the pattern has cleared the stop roller 38, thisroller immediately rises to isolate the next pattern of cartons from theprevious pattern of cartons. While a second pattern of cartons is beingassembled the first pattern is being compacted by the action of the ram68 compressing the cartons into abutting adjacency against the guide 67.When this compacting operation has been completed and the ram 68 set onits withdrawal movement, the stop roller 39 is lowered and the compactedpattern of cartons is fed into a stacking device which will be describedpresently.

During the compacting and feeding operation for the first describedpattern of cartons, the second pattern of cartons is being assembledadjacent stop roller 38 and between the side guide rails 59 and 60. Inthe second pattern the sequence of assembling the cartons is reversed tothe first pattern so that when the patterns are stacked there will be aninterlocking relation created as is well understood in this art. It isnot believed necessary to repeat the sequence of movement of the controlguides 37, except to say that in making up the second pattern oartons C9and C10 are directed into position with the guides in the positionrepresented by broken lines 5-6. Cartons C11 and C12 are positioned withthe guides 37 in the respective positions represent by broken lines 7and 8. Cartons C13 and C14 are positioned with the guides 37 in therespective positions of the broken lines 1 and 2, and finally cartonsC15 and C16 are positioned when the guides have moved to the positionrepresented by the broken lines 5*6. So long as the subject pattern ofeight cartons is called for the control guides 37 will fan back andforth as above described first for one pattern and then for theinterlocking pattern layout.

It can be appreciated that the groups of load supporting rollers 31, 32and 33 will greatly accelerate the rate of handling cartons, because anumber of different operations can be performed simultaneously in frontof the stops 38 and 39. That is to say, while a pattern of cartons isbeing comp-acted a second pattern of cartons can be collecting, andwhile the patterns of cartons are being fed into the stacking device insequence a third pattern can be readied for assembly, all withoutinterference. The disclosure last above described in connection withFIGS. 1 and 11 represents means for feeding patterns of cartons into astacking device, and in its broadest sense this portion of thepalletizing apparatus A can be thought of as a feeder for the stackingdevice now to be described.

Referring now to FIGS. 1 and 8, it can be seen that the stacking deviceB is positioned at the end of the carton pattern forming table such thatan elevator frame 100 is positioned initially such that its group ofcarton supporting rollers 101 are in the plane with the cartonsupporting rollers 33 in the compacting and loading section previouslydescribed. The elevator frame 100 is supported by the ram 102 '(FIG. 9)of an elevator hoist unit 103. The elevator hoist unit 103 is supportedon suitable fioor engaging beams 104 which are part of a general framecomposed of beams 105 which are supported on the beams 104 as well as onother beams 104a. Thus a rigid frame work is created for the operatingcomponents of the stacking device B. The elevator frame 100 is preventedfrom twisting out of proper alignment by means of a stabilizing deviceshown in FIG. 12. This device includes a stabilizer projection 106running between rollers 107 carried in a frame 108the frame 108 issupported between cross members 109 which are, in turn, supported fromthe beam structure previously described. It can be seen in FIG. 8 that asafety chain 110 is connected be tween a frame member 109 and theelevator frame 100 so that the elevating ram 102 can not exceed apredetermined elevation. It can be seen in FIG. 9 that the ram 102 worksin a cylinder 102a, and that the cylinder has an extension 106a whichengages in the stabilizer 106 for purposes of maintaining properalignment between the cylinder 102a and the elevator frame 100.

The elevator rollers 101 are adapted to be driven at certain times by adrive belt 111 when the elevator frame 100 is in its lowermost position.The drive belt is operatively supported (FIGS. 2, 8 and 9) on endpulleys 112 which are supported in a suitable frame structure 113mounted from the main beams 103 as can be seen in FIG. 2. The belt 111is trained over a drive pulley 114 which is driven by a suitablesprocket chain 115 from motor means 116 supported on a leg 28 of thetable frame shown in FIG. 3. The motor means 116 is of reversing type sothat the belt 111 can at proper times be' directionally controlled forturning the rollers 101 in the elevator frame 100 either to bring thepattern of cartons on to the elevator, and to discharge a loaded palletfrom the elevator or to reverse the rollers for the purpose of initiallybringing in an empty pallet upon which a stack of cartons is to bedeposited.

The stacking device B as is shown in FIGS. 8 and 10 includes a pair ofcarton supporting carriages 117. The carriages are identical but formedfor right and left hand assembly, and it will be appreciated that thesame reference numerals will be used on similar parts in order tosimplify the description. As can be seen best in FIG. 10, each carriage117 includes a base frame 118 made up of longitudinal and transversemembers, and this frame carries wheels 119 which are adapted to run onthe inner flanges of the main longitudinal beams 105. Each base frame118 is provided with a pair of vertical columns 120 which are adapted tosupport a channel member 121. The channel member 121 must be ofsufiicient structural ability, along with the columns 120 and the baseframe 118, to form a rigid support for a plurality of tines forming aplane which is substantially tangent to the rollers 101. Thus, supportrollers 101 on the elevator frame can be brought up very close to theunderside of the tines 122 to minimize any vertical difference in thetine surface relative to the roller surfaces. It can be observed in FIG.8 that the carriages 117 are operated by piston cylinder motor means inwhich the cylinder 123 is carried in a central longitudinal extendingchannel 124 and the piston rod 125 is connected to a fixed arm 126 onthe carriage. The piston cylinder motor means 123 are operated in unisonso that the carriages 117 move in and out relative to the elevator frame100 at the same time. Since the tines 122 of the carriages 117 areadapted to support the pattern of cartons, and since the tines must beremoved from such support each time a new layer of cartons is brought tothe stacking device. it is necessary that the tines be withdrawn fromthe carton supporting position and in order to accomplish this thecartons must be retained so as not to move outwardly with the tines 122.This is accomplished by means of providing a pair of holding dams 127.Each dam 127 is carried on a pivoting frame 128 having its lower endpivotally supported in a suitable bracket 129 as can be seen in FIGS. 8,9 and 13. The pivot frames 128 are provided midway of the verticalheight with a cross member 130 for the purpose of cooperating with aretractable locking plate 131. When the locking plate 131 engages thecross member 130 the holding dams 127 are vertically positioned with thedams 127 closely adjacent the pattern of cartons supported on the tines122. The locking plate 131 is pivotally mounted between a pair of plates132 carried on the central channel 124, and the pivot shaft 133 for thelocking plate 131 carries a depending arm 134 to which is connected anactuating spring 135. It can be observed in FIG. 13 that the spring 135,being anchored to the central channel 124, constantly urges the arm 134in a direction to lift the locking plate 131 upwardly so as to interceptand prevent the cross member 130 in the pivot frame 128 from passingback over the locking plate 131 once it has moved rightwardly to thelocking position.

It can be appreciated that the holding dams 127 must be coordinated withthe operation of the carriages 117, and this is accomplished in thefollowing manner: As can be seen in FIG. 8, when the carriages 117 arein their retracted or outermost position each thereof is provided withan abutment element 136 which is engaged with a tab 137 on the lower endof the arm 134, thereby holding the locking plate 131 in its retractedposition so that the pivot frames 128 can be drawn backwardly by aspring 138 to rest against a stop 139. As the carriages 117 moveinwardly toward each other the abutment elements 136 move inwardlythereby freeing the arms 134, under the influence of spring 135, topermit the stop plates 131 to move to locking positions. However, theplates 131 can not move to locking positions until the cross member 130in the pivot frames 128 has cleared the top edge of the locking plates.Once this clearance has been established the locking plates will snapupwardly and the curved end edges 131a on each thereof will apply asuitable holding engagement so that the pivot frames 128 will remaininwardly in binding contact with the cartons. As the frames 117 returnto the outward position of FIG. 8 the dams 127 are not freed from cartonengaging positions until the tines 122 are very nearly at the withdrawnposition, at which time the abutment elements 136 engage the tabs 137 onthe arms 134 of the locking plates 131 to withdraw the locking platesand thus free the pivot frames 128 so that the dams 127 will be removedfrom the possibility of interfering with the handling of the cartons.

It will be observed in FIG. 14 that the elevated frame 100 is providedwith a pair of coordinated stop gates 140 and 141, gate 140 beinglocated at the carton feed side of the stacking device B and the gate141 being located at the outlet side of the stacking device. Each gateis comprised of a longitudinal channel member mounted by suitableactuating arms 142 and 143 respectively about the pivot axis of theadjacent elevator rollers 101. The arms 142 and 143 are interconnectedby an actuating rod 144, and the rod 144 is powered by a suitable pistoncylinder motor means 145. It will be observed that when the gate 140 isin its full line position for stopping cartons the gate 141 is in itsretracted position. The reverse coordination of these gates is shown inbroken outline.

It has previously been pointed out that the rollers 101 in the elevatorframe 100 are driven in the proper direction by the drive belt 111 whent he elevator frame 100 has been lowered so that the rollers 101 engagethe drive belt. When the elevator frame 100 is raised it is desirablethat the rollers 101 be stopped. This is accomplished by means of abrake device which is shown in FIG. 15. The brake device includes abrake beam 146 having brake lining 147 adapted to engage the rollers.The brake beam 146 is maintained in proper attitude for engaging all ofthe rollers 101 simultaneously by pivot arms 148 carried in the frame100. The pivot arms 148 are so positioned with respect to the brake beam146 that a spring 149 can be utilized to lift the brake beam 146 intoproper braking position. Removing the brake pressure is accomplished bya retract arm 150 connected to the brake beam at link 151 and having itsopposite end 152 located in a position to engage a fixed striker 153(FIG. 8) mounted on the the cross member 109. It can be appreciated thatas the frame 100 descends relative to the fixed striker 153, the retractarm 150 pivots in a direction to draw the brake beam 146 inwardlyagainst the action of the spring 149 so that the rollers 101 are freefrom braking restraint and can be freely driven by the belt 111.

Turning now to the views of FIGS. 16A through 16F, t can be seen thatthe components of the stacking device B have a predetermined sequence ofoperation which will now be described. In FIG. 16A the carriages 117 arewithdrawn so that the dams 127 are free to pivot to open positions. Thisallows the elevator frame to pass upwardly between the dams 127 to therequired heighth such that the tines 122 (FIG. 16B) may be insertedunder the first layer of cartons. As the tines 122 pass under thecartons the dams 127 move in and retain the cartons in compact relationon the tines 122. This action allows the hoist to descend empty toreceive a second layer. Hoisting the second'layer (FIG. 16C) brings thecartons up under the tines 122 to the position shown in FIG. 16D. Atthis time the carriages 117 withdraw but the dams 127 remain in clampedposition against the cartons until the tines 122 are fully withdrawn andthe top layer is allowed to drop only a short distance onto the secondlayer of cartons. In FIG. 16E the elevator frame 100 has raised bothlayers to the proper heighth so the tines 122 may be inserted under thetwo layers upon reversal of the carriages 117. The carriages again runinwardly to insert the tines 122 under the two layers and close the dams127 as before. The elevator frame 100 again descends to receive a thirdlayer, and in FIG. 16F the third layer is brought up to a position wherethe tines 122 may again be withdrawn. The cycle of events as abovedescribed is repeated as many times as is needed to build up a multiplelayer of cartons. The number of layers is predetermined and under thecontrol of counting means in the box 155 (FIG. 8).

A typical apparatus of the character disclosed in FIGS. 1, 2, 4, 5, 6,8, 9 and 14 is provided With control means which is disclosed in greatlycondensed form in the electrical diagram of FIG. 17 and the schematiclayout in FIG. 18. The following will make reference to these views ofthe drawing, and any others deemed helpful will be referred to. It is,of course, understood that there will be a suitable source of compressedair and a fiuid pressure source which need not be shown.

It has been pointed out above that electric motor means 42 (FIG. 2)drives the supply conveyor 40 as well as the group of rollers 31constituting the carton receiving section of the table of loadsupporting rollers. A separate electric motor means 54 is provided todrive the turning roll 34. Motor means 55 drives the group of rollers 32in the pattern collecting section of the table and the group of rollers33 in the compacting and loading section of the table. Fluid pressuremotor means 90 (FIG. 6) controls the pattern guides 37, air motor means76 (FIG. 4) operates the compacting ram 68, air motor means 64 and 64'(FIG. 2) operate the respective stops 38 and 39, air motor 145 (FIG. 14)operates the gates and 141, fluid pressure motor means 102 (FIG. 9)operates the hoist 103, and electric motor 116 (FIG. 2) drives the belt122 for driving the hoist rollers 101.

If it is assumed that the apparatus is just starting up, the operatorcloses the master switch 200 (FIG. 17) which supplies suitable current(say 110 volt A.C.) to the various electric eyes PC1, E1, E2, E3, E4 andE5 stationed about the apparatus in FIG. 1, but represented collectivelyat 199 in FIG. 17. Concurrently an hydraulic pressure pump (not shown)is started and brings hydraulic fiuid up to operating pressure foractuating various motor means in the apparatus, such as motor means 90driving the pattern control guides 37, the elevator ram 102, and themotor means 123 for actuating the carton supporting carriages 117. Motormeans 64, 64', 76 and are operated by compressed air. After a desiredtime, a time delay unit 201 closes its contact 202 to complete thesupply of current to the various means, switches, and devices providedto handle the operation, either manually or automatically, as may beselected at switch 203.

9 This activation by switch 203 will condition the roller table A andelevator hoist unit B to go into operation, and will start electricmotors 54, 55 and 116. No cartons will be fed to the table A untilelectric motor 42 is started to drive the belt 41 or other means, aswell as rollers 31 in the table, by closing switch 204.

It is assumed also that the deflectors 37 are in the position 1 as inFIG. 11 and that the apparatus is programmed for forming layers in theorder and sequence shown in FIG. 11. The incoming cartons C1, C2, C3,etc. will pass the electric eye PCl closing and opening its contact PC1Ato signal a counting relay in the box 93 to step around and signal thefluid pressure motor 90 through control valves represented (FIG. 17) bysolenoids to move the deflectors 37 in the sequential order described inconnection with FIG. 11. The cartons are collected against stop roll 38,some being turned by the combined action of the roll 34 and sideabutments 35. As the first carton reaches stop roll 38 it breaks thelight beam for eye E1 that opens contact ElA. At the proper time in thecounting cycle stop roll 38 is retracted by actuation of its air motor64 through a solenoid control and when the light beam from electric eyeE1 is clear the eye contact ElA closes to cause air motor 64 to raiseroll 38 to stop the second group of cartons, as shown being assembled inFIG. 11. The first group of cartons runs into stop roll 39 and breaksthe light beam from electric eye E2 which closes its contact E2A whichsignals the compacting ram air motor 76 to move the ram 68 in forcompacting the cartons and in this movement it will open limit switchLSA and in the end position actuate a limit switch LSB Which willreverse the air motor 76 and signal air motor 64' to lower stop roll 39so that the compacted cartons may proceed on to the elevator rollers101. The elevator is provided with a pair of interconnected gates140-141 subject to movement by the motor means 145. At this stage in thecycle of operation gate 141 is up and gate 140 is retracted.

The feed of the cartons onto the elevator rollers 101 is possible whenthe frame 100 is in its lowest position, when the gate 140 is retracted,and when the electric eye E3 is not blocked, such as by the presence ofa pallet or other cartons. As the group or layer of cartons clearselectric eye E2 the motor means 64 for stop roll 39 will raise the sameto catch the next following group of cartons. When the cartons move intothe elevator unit B and block the electric eye E3 the contact E3A willclose and hoist motor means 102 will be signalled by switch means in box155 to rise. This being the first layer in a load, the carton supportingcarriages 117 will move from the out positions by actuation of motormeans 123 after the hoist 103 has elevated the cartons to its. maximumheighth position so that they are carried above the level of the tines122. The motion of the hoist 103 is transmitted by cable 157 (FIG. 8) toa series of cams on a rotary shaft (not shown) in the counter box 155.The shaft in the box 155 is rotated oppositely to the tension in cable157 by a motor (spring tension type) 158 so that as the hoist 103descends the rotary shaft will follow the movement and actuate suitablemicroswitches.

When the hoist 103 reaches the top position, a switch in box 155 willsignal the motor means 123 to move the carriages 117 inwardly so thatthe tines 122 slide under the cartons. At the proper in position oftines 122 the limit switches LS4 are actuated to stop the carriages andsignal the hoist 103 to lower and receive a second layer of cartons. Theraising of the second and following layers will be slightly differentdue to a cam in the box 155 which will stop the hoist 103 when the topsurfaces of the layer of cartons is just below (about A") the tines 122.Upon stopping the hoist 103 at the latter position, a signal will besent to the motor means 123 to reverse and withdraw the carriages 117.The withdrawal of the carriages will result in actuation of limitswitches LS2 to signal the hoist 103 to continue up to its top positionwhere it supports both layers. The hoist reaching the top position willby cable 157 (FIG. 8) signal the carriages 117 to move inwardly so thatthe tines 122 support the new load.

This cycle keeps up while a counter in box 155 counts off the desirednumber of layers wanted in the stack. When the count has been satisfied,stop roll 39 will not be allowed to drop again until the stack on thehoist is removed. Thus, when the hoist 103 gets to the bottom on itslast trip and when it blocks the electric eye E4, the hoist table havingtaken on a pallet P, it will be signalled to rise until it stops justunder tines 122. At this point, a cam switch in box 155 will stop thehoist and move the carriages 117 out. Actuation of the out limitswitches LS2 will indicate that .the hoist 103 can lower to its downposition, and when it reaches the position the hoist rollers 101 willengage a moving belt 111 driven by motor means 116. Simultaneously, thestop gates -141 will be actuated by air motor means to hold gate 140(FIG. 14) raised and gate 141 lowered. The rollers 101 are driven tourge the pallet loaded with layers of cartons out of the apparatus ontoany suitable take-away conveyor or onto a suitable lift truck or bed ofa take-away conveyance. When the loaded pallet has cleared the electriceye E3, a signal will be receeived by the motor means 145 to lower gate140 and raise gate 141 so that a repetitious cycle of loading anotherpallet can take place in accordance with the foregoing description.

In FIG. 19 there is shown a modified apparatus in which means isprovided for bringing empty pallets into the stacking unit B and fortaking loaded pallets out. Whereever parts and components are shown inthis view that are similar to the parts and components seen in FIG. 1similar reference numerals will be applied. Previously presenteddescription will, therefore, not be repeated in the interest of brevity.

The apparatus of FIG. 19 includes a conveyor frame for supporting loadcarrying rollers 161 that may be power operated or may be free turning,as desired. To one side of the frame 160 there is a platform 162 uponwhich are placed the empty pallets P, either by hand or by a fork-lifttruck. The platform 162 is connected by slide members 163 to the frame160 so that each pallet P can be conveniently moved into position asshown by pallet P. Once the desired stack of cartons has been assembledin the stacking unit B, the pallet P is moved into the elevator frame100 and elevated to receive the carton stack. The loaded pallet islowered to the level of the frame 160 and is moved out to the positionof loaded pallet P where it may be removed by a fork-lift truck.

The apparatus of FIG. 19 is shown in connection with the formation of apattern of cartons different from the pattern formed by the apparatus ofFIGS. 1 and 11. This is intended to illustrate the variations of cartonpattern control that is available, although the control means describedin FIG. 17 is related to the apparatus of FIG. 1.

The apparatus of FIG. 20 illustrates a modified form of apparatus inwhich a different carton pattern may be made up. Similar parts andcomponents in this view will be denoted by reference numerals used inFIG. 1. The prinicipal difference resides in the formation of layers of14 cartons instead of 8 cartons.

The apparatus of FIG. 21 illustrates a further modification in whichparts and components similar to those in FIG. 1 will be denoted bysimilar reference numerals. Principally the modified apparatus ispreprogrammed to make up layers of nine (9) cartons and in elfectingthis result, the carton turning roll is divided into two sections 164and 165 with a bearing 166 disposed therebetween. Section 164 isprovided with a drive sprocket 167 and section 165 has a drive sprocket168 whereby separate motor means, like motor means 54 in FIG. 2, may beprovided for rotating either roll section or rotating the sections atdifferent speeds or in reverse directions so that 1 1 the cartonsdirected by guides 37 over the adjacent ends may be turned from anend-on position as carton C17 t a cross-wise position as carton C18.

In the various forms of apparatus illustrated herein, the patterncontrol is predetermined to alternate the carton patterns so that thefinal stack will be interlocked- However, it is contemplated that thepatterns may be made up without reversing so that there will be nointerlocking layers.

It should now be understood in what manner the apparatus is intended tofunction to produce the advantages enumerated above. Having describedcertain forms of apparatus and a preferred form, it is intended toinclude variations within the spirit and scope of the appended claims.

What is claimed is:

1. In carton palletizing apparatus, a conveyor table upon which cartonsare accumulated in patterned layers, an elevator device adjactent saidconveyor table movable between a first position level with said conveyortable and other positions elevated above the first position, saidelevator device being provided with a plurality of rollers forming thecarton layer supporting surface, powered means located adjacent saidfirst position of said elevator device to be engaged by said rollers forrotating the rollers in a first direction, movement of said elevatordevice toward said other positions breaking the roller rotatingengagement, stop means on said elevator device operable selectively tointercept carton layer movement onto and olf of said supporting surfaceof rollers, means adjacent the first position level of said elevatordevice to feed an empty pallet upon said elevator device, said poweredmeans being reversible to bring the pallet under the stack of cartonlayers, said elevator device raising the pallet to accept the stack ofcarton layers, and control means to set said powered means for operationto rotate said rollers in said first direction for discharging theloaded pallet and begin receiving subsequent layers of cartons, cartonlayer holding means operable adjacent said other positions of theelevator device to support successive layers of cartons brought to saidother positions and form a stack of carton layers.

2. In carton palletizing apparatus the combination of elevator meansmovable between a first carton receiving and discharge position and asecond carton storing position, a plurality of power driven cartonsupporting rollers spaced apart on said elevator means to define aplatform surface, feeding means at said first position to feed cartonsonto said elevator platform surface, discharge means at said firstposition to receive cartons for discharge from said elevator platformsurface, carton storage means adjacent said second carton storingposition comprising reversibly movable frame means having a plurality oftines extending in a direction to occupy a position adjacent saidelevator platform surface in a first position and to retract fromadjacent said elevator platform surface in a seocnd position, said tineson said frame means being spaced apart to interleaf with said spacedcarton supporting rollers, and means to displace said frame means ofsaid carton storage means between said first and second positionsrespectively to take over carton support and to release cartons to saidcarton supporting rollers, said rollers being drivable in a forwarddirection to feed the cartons thereon and to discharge a completed stacktherefrom, the rollers also being drivable in the reverse direction tobring in an empty pallet from the discharge position upon which a stackof cartons is to be deposited.

3. The combination of claim 2 in which said carton storage meanscomprises a pair of opposed movable frame means each having a pluralityof tines which to gether support cartons.

4. The combination of claim 2 in which said elevator means is providedwith cooperating gate means adjacent said feeding means and dischargemeans, power operated means adjacent said first elevator cartonreceiving and discharge position to engage and drive said cartonsupporting rollers for moving cartons, and brake means on said elevatormeans to stop roller rotation upon elevator movement toward said secondcarton storing position.

5. The combination of claim 2 in which alignment means is operablymounted adjacent said second carton storing position and across the pathof movement of said movable frame means, said alignment meansintercepting the cartons on said tines upon retraction of said tines andbeing movable to a position causing the cartons to remain substantiallyaligned with said elevator means.

6. The combination of claim 5 in which means in said apparatus isoperably mounted to retain said alignment means in said carton aligningposition, said retainer means being released by movement of said framemeans toward its retracted position.

References Cited UNITED STATES PATENTS 1,747,465 2/ 1930 Cameron.

2,168,191 8/ 1939 Bergmann.

2,814,397 11/1957 Connell 1- 214-62 2,827,999 3/1958 Raynor 198-342,997,187 8/1961 Burt 214-62 3,038,615 6/1962 Roth et a1 214-62 X3,053,402 9/1962 Russell et a1. 214-62 3,074,595, 1/1963 Boiler.

FOREIGN PATENTS 185,579 10/1963 Sweden.

GERALD M. FORLENZA, Primary Examiner.

R. I. SPAR, Assistant Examiner.

US. Cl. X.R.

